Systems and methods of affixing multiple pouches to create a bellows device

ABSTRACT

A bellows device can contain fluid product, such as gasses or liquids. The device can include a series or plurality of pouches attached or otherwise operatively affixed in a manner that provides fluid communication between the pouches to facilitate expansion and contraction, much like an accordion. One or more of the pouches can include one or more apertures or holes defined in one or more portions of a panel portion. One or more affixation patches can be included to provide the structure for attaching the pouches in a serial manner to define the bellows device to facilitate fluid communication between the pouches. One or more apertures or holes are defined in the patch for alignment with the aperture of a first pouch, and an aperture of an adjacent second pouch, to facilitate fluid communication between adjacent pouches.

RELATED APPLICATIONS

This Application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/233,732, filed Aug. 16, 2021, which is hereby fully incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to flexible pouches and, more particularly, to bellows devices, and methods for manufacturing and using bellows including a plurality of attached pouches.

BACKGROUND OF THE INVENTION

Current implementations of bellows devices generally include connecting two or more pouches with two-sided adhesive tape. However, the cleaning process required for the adhesive tape can be a tedious process that can result in structural failures. In addition, the joinder of pouches in conventional bellows devices can create a rigid area that is more susceptible to fracturing around the joinder area, especially when the bellows are extensively expanded and contracted with use over time. Heat sealing the outer layers of barrier pouches together, which typically have Polyester or Nylon on the outside, would be impractical.

As a result, there is a need for a device that substantially solves the above-referenced problems with conventional designs, configurations, and manufacturing methods for bellows devices made from flexible packaging materials.

SUMMARY OF THE INVENTION

It can be desirable to have a series or plurality of flexible pouches that are operatively connected such that a fluid product, e.g., gas or liquid, flows back and forth (or one way) between the series of pouches provided in operative fluid communication with one another. Further, it is desirable to have the pouches connected at their respective panels, as opposed to their tops, bottoms, or sides. This panel orientation allows the pouches to expand and contract much like an accordion.

Pouches of various embodiments of the present invention can be constructed of a multi-layer film that has a sealant layer on the inside and a barrier film on the outside that is not typically heat sealable. To facilitate heat sealing of the individual pouches together, and maintain the barrier properties of the individual pouches, the affixation patches can be constructed of the same material as the individual pouches. With the patches constructed of the same material, or a material having barrier properties equal to the individual pouches, and the method of sealing the patches inside the pouch and then to adjacent patches, the bellows device is able to maintain the integrity of the intended or desired barrier protection characteristics while still being capable of heat sealing the adjacent patches and pouches together.

Various embodiments of the bellows device of the present invention can contain fluid product, such as gasses or liquids. The device can include a series or plurality of pouches attached or otherwise operatively affixed in a manner that provides operative fluid communication between the pouches. The plurality of pouches can include a first panel portion, and a second panel portion. One or more of the pouches can include one or more apertures or holes defined in one or more portions of a panel portion.

One or more affixation patches can be included to provide the structure for attaching the pouches in a serial manner to define the bellows device to facilitate fluid communication between the pouches. The one or more patches can be sealed to one or more of the panels on an inside surface within the internal cavity. One or more apertures or holes are defined in the patch for general alignment with the aperture of a first pouch, and an aperture of an adjacent second pouch to facilitate operative fluid communication between adjacent pouches. The affixation of adjacent pouches to facilitate fluid flow between the pouches can be achieved by providing the seal to attach a first patch to the first pouch and a seal to attach the first patch of the first pouch to the second patch of the second adjacent pouch to define an affixation region.

Heat sealing of the patches and pouches together fuses or melds the film material together to create a strong and consistent bond that solves many of the problems occurring with the making and using of conventional bellows devices. Further, the patches of embodiments of the present invention are flexible and reduce the chances of fracturing around the area joining the patches and the pouches.

The above summary is not intended to describe each illustrated embodiment, claimed embodiment or implementation of the invention. The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 shows a side view of a pouch (e.g., flexible) to form a portion or section of a bellows device, in accordance with embodiments of the present invention.

FIG. 2 shows a bottom view of the pouch of FIG. 1 , in accordance with embodiments of the present invention.

FIG. 3 shows a side view of an affixation patch to operatively attach adjacent pouches to form a bellows device, in accordance with embodiments of the present invention.

FIG. 4 shows a bottom view of the affixation patch of FIG. 3 , in accordance with embodiments of the present invention.

FIG. 5 shows a side view of the operatively sealing of an affixation patch to the inside of a pouch, in accordance with embodiments of the present invention.

FIG. 6 shows a bottom view of the affixation patch sealing of FIG. 5 , in accordance with embodiments of the present invention.

FIGS. 7-8 show a side view of operative sealing attachment of affixation patches and adjacent pouches to form a bellows device with fluid communication between the pouches, in accordance with embodiments of the present invention.

FIG. 9 shows a cross-section view of the operative sealing attachment of the affixation patch of FIG. 8 , in accordance with embodiments of the present invention.

FIG. 10 shows a side view of a bellows device including multiple, or a series of, pouches operatively sealed together with affixation patches, in accordance with embodiments of the present invention.

FIG. 11 shows a side view of a bellows device including multiple, or a series of, pouches operatively sealed together with affixation patches, with one or more of the pouches including a fitment or nozzle, in accordance with embodiments of the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, hatching or shading in the figures is generally provided to demonstrate sealed or crushed portions and/or integrated devices.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring generally to FIGS. 1-11 , embodiments of a bellows device 100 in accordance with the present invention are shown. Embodiments of the bellows device 100 can contain fluid product P, such as gasses or liquids of varying optional viscosities (e.g., high or low) and flows (e.g., steady or unsteady). The device 100 can include a series or plurality of pouches 102 (e.g., flexible pouches, 102 a . . . 102 n) operatively attached or otherwise affixed, e.g., via heat sealing, in a manner that provides operative fluid communication between the pouches 102.

The following patch affixation disclosure and techniques permit the operative sealable joining of pouches that include barrier films that are not typically capable of heat sealing together—e.g., Polyester or Nylon layers or materials on the outside of the pouches.

Referring to FIGS. 1-2 , the pouches 102 can include one or more panels or panel portions, including a first panel portion 12 (e.g., front) and one or more additional panels (e.g., back). Further, other panel portions can be included in addition to the identified panel portions to define the construct of the pouches—e.g., back, side, and bottom panel portions. One or more gussets G can be included to facilitate contraction and expansion of the pouch 102.

One or more of the pouches 102 can include one or more holes, passageways, or apertures 108 defined in one or more portions of a panel portion. The one or more apertures 108 can be punched, cut, predefined/preconfigured, or otherwise defined in one or more portions of a panel portion to be a size larger than necessary for the desirable product P to flow therethrough. The pouches 102 of the present invention can be made with gussets G to further increase, and permit variable adjustment of, the expandability, collapsibility, and volume of the entire assembly.

The pouches 102 of various embodiments of the present invention can be constructed of a multi-layer film that has a sealant layer on the inside (e.g., within the inner volume or cavity) and a barrier film on the outside of the pouch 102 that is not typically heat sealable. To facilitate heat sealing of the individual pouches 102 together, while maintaining the barrier properties of the individual pouches, affixation patches 104 can be constructed of the same or similar material as the individual pouches—e.g., a sealant layer/surface 104 a on one side for sealing to the pouch and a barrier layer on the other side/surface 104 b, opposite the sealant layer. In certain embodiments, the sealant layer 104 a can be constructed of Polyethylene and the barrier layer 104 b can be constructed of Polyester. With the patches 104 constructed of the same material, or a material having barrier properties equal to the individual pouches 102, and the method of sealing the patches 104 inside the pouch 102 and then to adjacent patches 102, the bellows device 100 is able to maintain the integrity of the intended or desired barrier protection characteristics while still being capable of heat sealing the adjacent patches 104 and pouches 102 together.

Referring generally to FIGS. 3-11 , one or more affixation patches 104 are included to provide the structure for operatively attaching the pouches 102 in a serial manner to define the bellows device 100 to facilitate operative fluid communication between the pouches 102. The one or more affixation patches 104 can be constructed of one or more film materials and/or layers to define flexible patches 104. Embodiments including flexible patches 104 can reduce the chances of fracturing around the area sealing or joining the patches and the pouches.

One or more seals 106 can define end, edge, or side seals to construct the pouches 102 such that an internal cavity or volume V is provided to contain the product P. Heat sealing of the patches 104 and pouches 102 together fuses or melds the film material together to create a strong and consistent bond that solves many of the problems present with the making and using of conventional bellows devices.

As shown in FIGS. 3-4 , The one or more affixation patches 104 can include the first sealant layer/surface 104 a, the second barrier layer/surface 104 b, a body portion 104 c, an edge portion 104 d, and one or more apertures or holes 110. The patches 104 can take on various sizes and shapes, including circular, oval, rectangular, square, triangular, can include undulating edges, and the like.

Referring to FIGS. 5-9 , the patch 104 (e.g., seal surface/layer 104 a) can be affixed at seal 112 to one of the panels on an inside surface within the internal cavity V of the panel. The one or more apertures or holes 110 are defined in the patch 104 for alignment with the aperture 108 of a first pouch 102, and an aperture 108 of an adjacent second pouch 102 to facilitate fluid communication between adjacent pouches 102.

FIGS. 7-9 illustrate exemplary pouch/patch/aperture alignments and sealing configurations for the device 100. As depicted in FIGS. 8-9 , the affixation of adjacent pouches 102 to facilitate fluid flow between the pouches 102 can be achieved by providing the seal 112 to attach a first patch 104 (e.g., via surface/layer 104 a) to the first pouch 102 a and a seal 114 to attach the first patch 104 of the first pouch 102 a to the second patch 104 of the second adjacent pouch 102 b to define an affixation region 120.

The patch 104 can be constructed of the same material as the corresponding pouch 102 and the aperture 110 can be measurably larger than the aperture 108 made in the pouch 102 to facilitate heat sealing inside the pouch 102, over the aperture 108. The patch aperture 110 is sized and shaped to facilitate the desired levels of fluid product flow between connected pouches 102. In certain embodiments, the one or more patch apertures 110 can include a single large hole, multiple smaller holes, one or more slits, or like structures and constructs to permit the desired flow of fluid product therethrough.

In various embodiments, the one or more patches 104 can be constructed of a material with at least two layers of film, one of which is the sealant layer 104 a (to facilitate sealing to the corresponding pouch panel), and one of which is an oxygen barrier layer 104 b, such as a Polyester or Nylon. In other embodiments with a higher level of barrier protection, the barrier layer can be constructed of Polyethylene, foil, and Polyester laminated together (e.g., via adhesive or extrusion lamination). Other known sealant and barrier surfaces/layers known in the art can be employed for the patch 104 construct as well, without deviating from the spirit and scope of the present invention. As such, seal bars can be employed that seal the patches 104 together to drive the heat from outside of the pouches through their opposing surfaces, thus avoiding sealing of materials other than the sealant layers 104 a of the patches 104 facing each other. However, in certain embodiments, it is desirable to leave one side of each pouch opened to allow a sealing apparatus, bar, platen, or the like to seal the patches 104 together directly over the patches from within the pouches.

In various other embodiments, the patch 104 material includes a two-sided sealable material. This material can include a continuous sealable strip of film running the length of the pouch (e.g., from one edge seal 106 to the opposite edge seal 106), and defining the patch 104, as the pouch 102 is made in order to remove the step of sealing a patch 104 in the pouches 102 later. In this case, the aperture or hole 110 in the patch film can be registered and centered with the aperture or hole 108 in the pouch while being sealed into the pouch 102 during the pouch making process. The two-sided sealable seal strip 104 can include perforations or multiple small holes that can be placed over the aperture 108 in the pouch. The seal that seals the strips 104 together would seal off any perforation or like small holes not captured within the seal area.

Further, if desired, more than one patch 104 (and respective aperture) or affixation/connecting points or regions 120 can be employed to increase or alter fluid flow between the attached pouches. The size or configuration differences between the size of the pouch aperture 108 hole and the patch aperture 110 is specifically designed to ensure there is sufficient sealable material when the patch aperture 110 is centered over the pouch aperture 108—e.g., to heat seal to the opposing/adjacent patch in the opposing/adjacent pouch.

Referring to FIGS. 10-11 , a series of pouches 102 (e.g., 102 a-102 d) affixed with the respective patches 104 at affixation regions 120 define the overall bellows device 100 in accordance with embodiments of the present invention. The patches 104 and respective apertures 108, 110 can be aligned for the multiple pouches, or offset from one another, depending on the fluid flow (e.g., illustrated with arrows) needs and implementations. For example, pouch 102 a can include an aperture 108 aligned with aperture 108 of pouch 102 b, with a first affixation patch 104 (with aperture 110) aligned and sealed in pouch 102 a and a second affixation patch 104 (with aperture 110) aligned and sealed in adjacent pouch 102 b to provide operative fluid communication and flow between the two joined pouches 102 a, 102 b. The same aperture, patch, and pouch construct, alignment, and sealable joinder can be provided between pouch 102 b and pouch 102 c, and between pouch 102 c and pouch 102 d.

As shown in FIG. 11 , one or more of the pouches 102 of the device 100 can include one or more nozzles, fitments, or like devices 122 to facilitate filling of one or more of the pouches 102 with fluid (e.g., gas, or liquid, product P) within the internal cavity. In certain embodiments, the device 122 can be a valve (e.g., one-way valve) or like device to release/adjust internal pressure, facilitate off-gassing, etc.

Side and bottom panel portions, gusseted or non-gusseted, may also be included. The panel portions are often referred to as webs, films, or layers. References to “top,” “bottom,” “front,” “side,” “back” and the like are for illustrative purposes only and are not meant to limit the scope of the disclosed invention.

The device according to the invention can include pouches constructed, in whole or in part, of flexible, rigid, semi-rigid, or semi-flexible materials or panels. Briefly, the pouch panel portions are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes or polypropylenes laminated with other materials such as nylon, polyester, and like films. To provide for increased barrier properties, embodiments can use composite or laminate layers of said materials and material of the like. Generally, in such composite or laminate embodiments, a material having preferred sealing characteristics can be joined, bonded, or laminated to a material having a different preferred characteristic (e.g., beneficial oxygen barrier properties). Regardless, single sheets, composites/laminates, and a myriad of other materials and techniques known to one skilled in the art may be implemented based on particular usage and manufacturing needs without deviating from the spirit and scope of the present invention.

In various embodiments, the first panel portion and/or the second panel portion will be formed of one contiguous web material. In other embodiments, at least one of the panel portions can be distinct web materials joined or sealed to other respective panel portions to form the pouches or devices of the present invention.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing/forming the present invention to those specifically defined herein. A myriad of various unspecified steps and procedures can be performed to create or form the inventive pouches and devices. Further, features and aspects of the various embodiments described herein can be combined to form additional embodiments within the scope of the invention even if such combination is not specifically described herein.

References to front, back and side panels for the device and pouch and device formation embodiments described herein are provided to facilitate an understanding of orientation and direction and are not intended to be limiting. For instance, closure devices, access devices, filling devices, seals, and other structures or portions of the device, can be provided to or along any portion of the device regardless of the references herein to front, back, side, bottom and the like. 

What is claimed is:
 1. A bellows device, comprising: a first pouch including at least one first aperture and a first internal volume; a second pouch including at least one second aperture and a second internal volume; and at least one affixation patch including at least one patch aperture and operatively coupled with the first pouch at an affixation region to align the at least one first aperture and the at least one second aperture to operatively join the first pouch and the second pouch to provide operative fluid communication between the first internal volume of the first pouch and the second internal volume of the second pouch.
 2. The device of claim 1, wherein the at least one affixation patch is constructed of a flexible material.
 3. The device of claim 1, wherein the at least one affixation patch includes two or more apertures.
 4. The device of claim 1, wherein the at least one affixation patch is operatively coupled with the first pouch via heat sealing.
 5. The device of claim 1, further comprising a third pouch including at least one third aperture and a third internal volume.
 6. The device of claim 5, further comprising a second affixation patch including at least one second patch aperture and operatively coupled with the second pouch.
 7. The device of claim 6, wherein operative fluid communication is provided between the first internal volume of the first pouch and the third internal volume of the third pouch.
 8. The device of claim 5, further comprising a fourth pouch including at least one fourth aperture and a fourth internal volume.
 9. The device of claim 6, wherein the second affixation patch includes two or more apertures.
 10. The device of claim 6, wherein the second affixation patch is operatively coupled with the second pouch via heat sealing.
 11. The device of claim 1, wherein the at least one affixation patch includes at least a first surface and a second surface, with the first surface constructed of a heat sealable material and the second surface constructed of a material having oxygen barrier properties.
 12. A bellows device having a series of operatively connected flexible pouches, comprising: a first flexible pouch including at least one first aperture and a first internal volume; a second flexible pouch including at least one second aperture and a second internal volume; a third flexible pouch including at least one third aperture and a third internal volume; a first affixation patch including one or more first apertures and operatively coupled with the first flexible pouch to align the at least one first aperture and the at least one second aperture; and a second affixation patch including at least one second aperture and operatively coupled with the second flexible pouch to provide operative fluid communication between the first internal volume of the first flexible pouch and the third internal volume of the third flexible pouch.
 13. The device of claim 12, wherein at least one of the first affixation patch or the second affixation patch is constructed of a flexible material.
 14. The device of claim 12, wherein at least one of the first affixation patch and the second affixation patch includes two or more apertures.
 15. The device of claim 12, wherein at least one of the first affixation patch and the second affixation patch includes a first surface constructed of a heat sealable material and a second surface constructed of a material having oxygen barrier properties.
 16. A bellows device having a series of operatively connected flexible pouches, comprising: a first flexible pouch including at least one first aperture and a first internal volume; a second flexible pouch including at least one second aperture and a second internal volume; a third flexible pouch including at least one third aperture and a third internal volume; a first affixation patch including one or more first apertures and operatively heat sealed with the first flexible pouch to align the at least one first aperture and the at least one second aperture; a second affixation patch including at least one second aperture and operatively heat sealed with the second flexible pouch to provide operative fluid communication between the first internal volume of the first flexible pouch and the second internal volume of the second flexible pouch; and a third affixation patch including at least one third aperture and operatively heat sealed with the second flexible pouch to provide operative fluid communication between the second internal volume of the second flexible pouch and the third internal volume of the third flexible pouch.
 17. The device of claim 16, wherein at least one of the first, second, and third affixation patches includes a first surface constructed of a heat sealable material and a second surface constructed of a material having oxygen barrier properties.
 18. The device of claim 16, wherein at least one of the first, second, and third affixation patches include two or more apertures.
 19. The device of claim 16, wherein the at least one of the first, second, and third affixation patches is constructed of a flexible material.
 20. The device of claim 16, wherein at least one of the first, second, and third flexible pouches include a fitment device. 